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GE AZ85E09DAC Technical Service Manual

Zoneline vertical air conditioners
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GE Appliances
Technical Service Guide
September 2010
Zoneline Vertical Air Conditioners
Model Series
AZ85E09DAC
AZ85H09DAC
AZ85E09EAC
AZ85H09EAC
AZ85E12DAC
AZ85H12DAC
AZ85E12EAC
AZ85H12EAC
AZ85E18DAC
AZ85H18DAC
AZ85E18EAC
AZ85H18EAC
AZ85W09DAC
AZ85W12DAC
AZ85W18DAC
31-9197
GE Appliances
General Electric Company
Louisville, Kentucky 40225
Case
Zoneline unit
Front

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Summary of Contents for GE AZ85E09DAC

  • Page 1 GE Appliances Technical Service Guide September 2010 Zoneline Vertical Air Conditioners Model Series AZ85E09DAC AZ85H09DAC AZ85E09EAC AZ85H09EAC AZ85E12DAC AZ85H12DAC AZ85E12EAC AZ85H12EAC Case AZ85E18DAC Zoneline unit AZ85H18DAC Front AZ85E18EAC AZ85H18EAC AZ85W09DAC AZ85W12DAC AZ85W18DAC 31-9197 GE Appliances General Electric Company Louisville, Kentucky 40225...
  • Page 2 If grounding wires, screws, straps, clips, nuts, or washers used to complete a path to ground are removed for service, they must be returned to their original position and properly fastened. GE Appliances Technical Service Guide Copyright © 2010 All rights reserved. This service guide may not be reproduced in whole or in part in any form without written permission from the General Electric Company.

  • Page 3: Table Of Contents

    Table of Contents Capacitor ....................................33 Circuit Boards Locator Views .............................26 Component Locator Views ............................23 Components ..................................30 Compressor ..................................44 Controls-Dip Switches ..............................11 Controls-Terminal Connections ..........................13 Drive Board ..................................31 Electrical Requirements ..............................6 Features and Operation..............................11 Indoor Fan Motor ................................36 Introduction ..................................4 Main Board ...................................30 Nomenclature ..................................
  • Page 4 Introduction Case Zoneline unit Front The Zoneline Vertical Air Conditioners are ideal for hotel/motel installations. Programmable for central desk control, electric heat, freeze sentinel, fan speed, and temperature limiting, these units allow for effi cient control of power usage. The Energy Management System is also available, providing automatic comfort at peak energy effi...
  • Page 5 Nomenclature Model Number AZ 85 H 12 D A C W 1 Engineering Revision Zoneline ® M = MEI Compressor W = Rechi Compressor Chassis Series C = Corrosion E = Cooling w/Electric Resistance Heat H = Cooling w/Heat Pump A = Revision and Electric Resistance Heat D = 230/208 V single phase...
  • Page 6 Electrical Requirements Wire Size and Breaker Size Warning: All wiring, including installation of the receptacle, must be in accordance with the National Electric Code, local codes, ordinances, and regulations. • Use only the wiring size recommended for single outlet branch circuit. •...
  • Page 7 Direct Connection 208 VAC 230 VAC 265 VAC – 7 –...
  • Page 8 Technical Data Heat Pump Model AZ85H12DACW1 IMPORTANT SAFETY NOTICE WARNING: Risk of electric shock. Can cause injury This information is intended for use by individuals possessing adequate backgrounds or death: Read all instructions and safety information of electrical, electronic and mechanical experience. Any attempt to repair a major before servicing this product.
  • Page 9 Electric Heat Model AZ85E12DACW1 IMPORTANT SAFETY NOTICE WARNING: Risk of electric shock. Can cause injury This information is intended for use by individuals possessing adequate backgrounds or death: Read all instructions and safety information of electrical, electronic and mechanical experience. Any attempt to repair a major before servicing this product.
  • Page 10 Cooling Model AZ85W12DACW IMPORTANT SAFETY NOTICE WARNING: Risk of electric shock. Can cause injury This information is intended for use by individuals possessing adequate backgrounds or death: Read all instructions and safety information of electrical, electronic and mechanical experience. Any attempt to repair a major appliance may result in personal injury and property damage.
  • Page 11 Features and Operation Controls-Dip Switches Dip Switches The dip switches are located behind the front case panel, and are accessible through an opening on the 6ZLWFKHV front of the unit. The left row of dip switches controls Temperature Limiting. The right row of dip switches controls the heat pump lockout, Freeze Sentinel, constant fan, Energy Management System, and indoor fan speed.
  • Page 12 All Electric Heat (Heat pump models only) When this switch is enabled (UP), heat pump operation is locked out, causing the unit to provide only electric resistance heat. ALL I 5 $OO (OHFWULF +HDW Freeze Sentinel (Requires room air sensor kit- RAVRMS) When this switch is enabled (UP), it turns OFF the freeze sentinel protection feature.
  • Page 13 Controls-Terminal Connections Main Board Terminal Strip Caution: Improper wiring may damage the Zoneline electronics. Damage or erratic operation may result. No common busing is permitted. A separate wire pair must be run from each separate controlling switch to each individual Zoneline. The terminal connections are located behind the front case panel.
  • Page 14 Central Desk Control (CDC) MAIN BOARD 24 V FAN (L) FAN (H) 5HG²9 $& RQO\ *UHHQ²/RZ 6SHHG )DQ *UHHQ²+LJK 6SHHG )DQ COOL %ODFN²5HYHUVLQJ 9DOYH <HOORZ²&RPSUHVVRU HEAT :KLWH²+HDWHU &RPPRQ²*URXQG GEA01248 When a CDC switch is connected to the main board terminal strip, the unit can be turned on and off from a remote location.
  • Page 15 Temperature Limiting Temperature limiting limits the lowest temperature that can be set for cooling and the highest temperature that can be set for heating. The dip switches are used to control temperature limiting. Temperature limiting is dependent on the Room Air Sensor (kit). If the Room Air Sensor (kit) is not installed, temperature limiting will not operate.
  • Page 16 The Freeze Sentinel is enabled by a dip switch and is dependant on the Room Air Sensor (kit). If the Room Air Sensor (kit) is not installed, the Freeze Sentinel will not operate. The FREEZE S dip switch must be down for Freeze Sentinel operation.
  • Page 17 Energy Management System The following conditions must exist for the Energy ROOM AIR SENSOR MAIN BOARD Management System to operate: • OCCUPIED dip switch is up. • Room Air Sensor (kit) is installed. MOTION SENSOR • Door Sensor (kit) is installed. •...
  • Page 18 Motion Sensor (kit) The motion sensor has a 2-wire circuit that is connected to the main board terminal strip. The motion sensor is an electronic sensor that, when motion is sensed, closes a switch (internal to the sensor), completing the motion sensor circuit. 0RWLRQ After the Energy Management System has seen 6HQVRU...
  • Page 19 Operation About Heat Pumps ON/OFF Switch (on some models) Heat pumps can reduce operating costs by WARNING: ON/OFF switch does not disconnect exchanging heat from the outside air-even when the power from all circuits. outside temperature is below freezing-and releasing that heat indoors.
  • Page 20 Automatic Defrosting of Indoor and Outdoor Coils During continued compressor operation, there is potential for ice to form on the indoor coil when in cool mode and for ice to form on the outdoor coil when in heat mode. The Zoneline is equipped with Automatic Defrost to eliminate this potential problem.
  • Page 21 Heat Mode Operation Note: • Minimum compressor/fans off time is 3 minutes +/- 10 seconds. • Heat pump will not operate if outdoor thermistor sees 25°F or less. • Heat pump and resistance heater(s) do not operate at the same time. •...
  • Page 22 The exhaust coils on the Zoneline should be checked regularly. If they are clogged with dirt or soot, they may be professionally steam cleaned by your GE service center. You will need to remove the unit from the case to inspect the coils because the dirt build- up occurs on the exhaust side.

  • Page 23: Capacitor

    Component Locator Views Front View Transformer Main Board Capacitor Power Cord Connector Resistance Heater Connector Vent Control Drive Board Indoor Coil (Continued next page) – 23 –...
  • Page 24 Left Side View Outdoor Air Thermistor Vent Control Outdoor Fan Motor Indoor Fan Motor Reversing Valve Reversing Valve Solenoid Indoor Coil Thermistor Thermostatic Drain Valve Outdoor Coil Thermistor (Continued next page) – 24 –...
  • Page 25 Right Side View Outdoor Fan Motor Indoor Coil Outdoor Coil Compressor – 25 –...

  • Page 26: Circuit Boards Locator Views

    Circuit Boards Locator Views Main Board CN1 - Indoor Coil, Outdoor Coil, and Outside Air Thermistors CN3 - Main Board to Drive Board Connector CN4 - Main Board to Drive Board Connector CN6 - Power from Drive Board (Continued next page) –...
  • Page 27 Drive Board CN103 CN102 BCN105 BCN104 BCN106 RY103 RY104 CN101 FU103 CN109 CN108 RY102 CN107 RY101 FU101 FU102 CN101 - Transformer FU101 - Transformer Primary (250 Volt - 4 Amp) FU102 - Fan Motors (500 Volt - 1 Amp) CN102 - Outdoor Fan FU103 - Transformer Secondary - (250 Volt - .5 Amp) CN103 - Indoor Fan CN107 - On/Off Switch...
  • Page 28 Slide-Out Chassis Front Panel Removal 5. Remove the 5/16-in. hex-head case ground bolt fastening the chassis to the base of the cabinet. WARNING: The case ground bolt, located at the front of chassis, must be installed to ensure proper 6. Remove the Phillips-head case ground screw grounding of the unit.
  • Page 29 8. Slide the chassis out from the front of the 2. Pull the chassis out of the front of the cabinet cabinet. approximately 2 inches. 3. Slide the chassis out from the side of the cabinet. Side Removal Note: If the slide-out chassis cannot be removed from the front, perform steps 1 through 6 of To remove the slide-out chassis from the front, then proceed with side removal.

  • Page 30: Components

    Components To remove the main board: Main Board 1. Remove the front panel. (See Slide-Out Chassis The main board is located behind the electronics cover. The front panel must be removed to remove 2. Unplug the power cord (if installed) at the the electronics cover and access the main board.
  • Page 31 Note: 7. Disconnect wire harnesses located at CN1, CN3, CN4, and CN6. • In the following step, the electronics cover is attached to the front bulkhead with 5 Phillips- 8. Compress the 6 compression pins, then pull head screws and 2 tabs. One tab is located on main board from the bracket.
  • Page 32 To remove the drive board: 4. Mark and disconnect the wiring from relays RY101, RY102, RY103, and RY104. 1. Remove the electronics cover. (See Main Board 5. Remove the Phillips-head screw and drive board Note: It may be helpful to observe the appearance ground wire from the front bulkhead.
  • Page 33 Capacitor Transformer The compressor run capacitor is attached to the The transformer supplies 24 VAC to the drive board front bulkhead with a strap and a Phillips-head at location CN101. Check for line voltage on the screw. The control cover must be removed to access power supply board at CN101 between pins 5 and 7.
  • Page 34 Electric resistance heat and heat pump operation Resistance Heater Assembly will never occur at the same time. The heater assembly consists of three 265 VAC or Models without heat pump feature will meet heating 230/208 VAC resistance heating coils fastened to- requirements by using electric resistance heating coils.
  • Page 35 3. Remove the 4 Phillips-head screws and the 6. Remove the 3 Phillips-head screws and the corner sheet metal panel fastened to the right indoor coil top panel. side of the indoor coil. 4. Disconnect the heater wire harness. Indoor Coil Top Cover 7.

  • Page 36: Controls-Dip Switches

    11. Mark and disconnect wires from the heater. Indoor Fan Motor 12. Remove the two 1/4-in. hex-head screws that The indoor fan is a permanently lubricated, variable attach each protector to the heater frame. speed DC motor. Indoor fan speed is selected in the 13.

  • Page 37: Main Board

    To remove the indoor fan motor: 5. Remove the 11 Phillips-head screws and the divider assembly from the left and right side of 1. Remove the unit from the cabinet. (See Slide-Out the unit. Chassis 2. Remove the electronics cover. (See Main Board.
  • Page 38 11. Remove the 3 Phillips-head screws and the 14. Remove the 4 Phillips-head screws, motor, and brace from the indoor fan motor bracket. motor rubber from the fan motor bracket. Motor Bracket Brace 12. Remove the 3 Phillips-head screws that attach the fan motor bracket to the fan housing.

  • Page 39: Outdoor Fan Motor

    To remove the outdoor fan motor: Outdoor Fan Motor 1. Remove the unit from the cabinet. (See Slide-Out The outdoor fan motor is a permanently lubricated, Chassis variable speed DC motor, using an internal speed 2. Remove the electronics cover. (See Main Board.
  • Page 40 4. Disconnect the outdoor fan wire connector 10. Remove the plastic wire tie that attaches the (CN102) from the drive board. (See outdoor air thermistor to the top of the fan Circuit Boards shroud. Locator Views 11. Remove the outdoor coil thermistor wire from 5.
  • Page 41 13. Remove the 9 Phillips-head screws (3 on each 15. Remove the 8-mm nut and the fan from the mo- side and 3 on top) that attach the fan shroud to tor shaft. the outdoor coil. 16. Remove the 4 Phillips-head screws and the fan motor from the fan motor angle.
  • Page 42 No Fan Operation 3. Single motor not operating. 1. Read the DC voltage at the main board wire a. Substitute new motor to the fan connector jumpers JP68 and JP72 (indoor fan motor), or on the drive board. JP65 and JP72 (outdoor fan motor). Use the b.
  • Page 43 Thermostatic Drain Valve Thermistors During the cooling season, the thermostatic drain valve remains closed to allow water to accumulate The main board uses input from 3 thermistors. in the base pan. The water is then picked up by the These thermistors are located on the indoor outdoor fan blade and blown into the condenser, coil, outdoor coil, and outdoor fan shroud.
  • Page 44 Compressor Reversing Valve The Zoneline compressor is a rotary type that The reversing valve operates on 265/230/208 VAC operates on 265/230/208 VAC. After the compressor and is used to switch the direction of refrigerant has cycled off, it will not attempt to restart for 3 fl...

  • Page 45: Troubleshooting

    Troubleshooting Self-Check and Force Mode The Zoneline unit incorporates a forced function feature so that components can be operated regardless of ambient conditions to allow testing of various components. To enter the self-check and force mode: 1. Disconnect the unit from power. 2.
  • Page 46 85E SERIES COMPRESSOR LINE BREAK HEATERS STEP LED1 LED2 I.D Fan O.D Fan MODE RY101 RY102 RY103 ¤ ¤ STOP Cooling ¤ ¤ Cooling ¤ ¤ Cooling ¤ ¤ Heater ¤ ¤ ¤ Heater-Pump ¤ ¤ : ON * : BLINK - : OFF 85W SERIES COMPRESSOR...
  • Page 47 Schematics and Wiring Diagrams 8500 Series Typical Wiring Diagram Refer to the mini-manual attached to the unit. Note: Refer to Yellow Universal Connector (Continued next page) – 47 –...
  • Page 48 8500 Series Typical Schematic Refer to the mini-manual attached to the unit. Note: Refer to Yellow Universal Connector UNIVERSAL CONNECTOR PROTECTOR SW201 FUSE Reverse Indoor Running Outdoor Valve Capacitor Comp. Sol. Motor Motor Motor O.L.P. CN108 CN103 CN102 Temperature limiting during COOL mode (all temperatures shown in °F) Down Min.

  • Page 49: Warranty

    This warranty is extended to the original purchaser and any succeeding owner for products purchased for use within the USA and Canada. If the product is located in an area where service by a GE Authorized Servicer is not available, you may be responsible for a trip charge or you may be required to bring the product to an Authorized GE Service location for service.

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